PARTIAL REPLACEMENT OF CEMENT BY FLY ASH …...This test is performed in accordance with IS 4031(part 1):1996. 100 g of cement sample is sieved manually on 90 microns sieve as shown

DOI:10.21884/IJMTER.2020.7003.QFYNI 25

PARTIAL REPLACEMENT OF CEMENT BY FLY ASH AND

ADDITION OF PLASTIC WASTE FIBERS IN CONCRETE

Shikha Sapehiya1, Arjun Kumar

1, Kanav Mehta

1, Akshit Mahajan

1

1Department of Civil Engineering, Vaishno College of Engineering, Thapkour (H.P.)

Abstract—A large quantities of waste materials and by-products are generated from

manufacturing processes, service and municipal solid wastes, etc. As a result, solid waste

management has become one of the major environmental concerns in the world. Fly ash and

plastic waste are two very common materials which causes disposal problems in very large

amount. Fly ash (FA) is produced in the process of electricity generation in large quantity and

becomes available as a by-product of coal based power stations. It is fine powder resulting from

the combustion of powered coal, it possesses good pozzolanic property. Plastic waste fibers

(PWF) are wastes from used polythene bags, tins, packets and rubber. This plastic waste leads to

pollute the environment. So it is very important to dispose these wastes without affecting the

environment.

This research addresses the suitability of FA and PWF in concrete as partial replacement of

cement and addition respectively, so as to eliminate the disposal problems of FA and PWF

and also to minimize the cost of concrete structural work.

In this work M20 grade of concrete is used for experimental analysis. The cement is

partially replaced by FA at 0%, 5%, 10%, and 15% by weight. Water cement ratio was kept

0.5 in all concrete mixes. 48 specimens of sizes 150*150*150mm and 300*150mm were made

for testing compressive strength and split tensile strength of the concrete. The strength of

specimens is tested after 7 and 28 days of curing. Results show the more strength of concrete

when replacing cement partially by FA than the ordinary concrete. Results also show that 10%

replacement of cement by FA gives maximum compressive and split tensile strength at 0.5%, 1%

and 1.5% addition of PWF. Also the replacement of cement by FA increases the workability of

concrete.

Keywords— Plastic waste, fly ash waste, pozzolanic, M20 grade, concrete. cement,

compressive, split, tensile.

I. INTRODUCTION

Concrete is the most broadly utilized development material on the planet, more so in the

developing countries, and there are global concerns such as depletion of non-renewable mineral

deposits and emission of the greenhouse gas associate with the fabricate of bond, which is the

essential restricting individual in the concrete. Therefore, the need for conservative and more

natural amicable cementing materials have expanded the enthusiasm for other cementing materials

that can be utilized as halfway or aggregate replacements of the typical Portland cement. Many

endeavors have been made to build the utilization of cement replacing materials in concrete

production because cement production consumes high energy and is responsible for 5% of

global carbon dioxide (CO2) emissions (one ton of cement produces about one ton of carbon

dioxide) and the utilize of cement replacing materials can also improve the act of concrete.

Many trade wastes and byproducts for example, fly ash, blast heater slag, and silica fume and

so forth are used as cement substitute materials in concrete production. Amorphous silicon dioxide

(SiO2) present in such pozzolanic materials leads to the configuration of additional calcium

International Journal of Modern Trends in Engineering and Research (IJMTER) Volume 07, Issue 01, [January– 2020] ISSN (Online):2349–9745; ISSN (Print):2393-8161

@IJMTER-2020, All rights Reserved 26

silicate hydrate (CS-H) when it reacts with calcium hydroxide (free lime formed during cement

hydration) and water. This is called secondary gel. This additional CSH, thus formed, increases

the concentration of the matrix and improves the pore structure leading to better toughness

of concrete and mostly of the time results in increase in strength also.

This use of industrial wastes has reduced the dumping land requirements and leads to creation

of wealth from waste.

Similarly agro-industrial wastes such as fly ash have been found to have good pozzolanic

properties. This is due to the occurrence of high SiO2 content in it and its amorphous nature,

which is governed by the burning conditions and usually controls the improvement in strength

and resilience of the end product .

II. METHODOLOGY

Procurement of FA from electricity power plants.

Lab testing of characteristics of FA and WPF such as specific gravity, physical state, odour, aspect ratio etc.

Preparation of design mix of M20 grade using relevant code.

Preparation of different concrete mix using FA as incomplete substitute of cement by 0%,

5%, 10%, 15%.

Addition of WPF beginning 0% to 1.5% by the weight of concrete.

Relative study of compressive and split tensile strength of concrete mix.

III. EXPERIMENTAL PARAMETERS

The experimental program extended in this research work has been carried out in accordance with

Indian Standards laid by Bureau of Indian Standards. All the materials used in this project satisfy

the standards given in their respective codes. Tests performed during this experimental research

are also in accordance with the standards given in IS codes.

[1] Testing:

A. Normal Consistency of Cement

It is the percentage water of cement paste at which of the paste becomes such that the plunger in

a specially designed apparatus (Vicat’s apparatus having plunger with 10 mm diameter and 50

mm length as per IS 5513:1996) penetrates a, depth 5 to 7 mm measured from the bottom of

mould. This test is performed in accordance with IS 4031(Part 4):1988. Take 400 g of cement

and place it in the enameled tray. Mix about 25% water by weight of dry cement thoroughly to

get a cement paste. Total time taken to obtain thoroughly mixed water cement paste i.e.

“Gauging time” should not be less than 3 minutes and not more than 5 minutes. Fill the Vicat’s

mould, resting upon a non-porous base plate, with this cement paste. After filling the mould

completely, smoothen the surface of the paste, making it level with top of the mould with the

help of trowel. Place this whole assembly (i.e. mould + cement paste + base plate) under the

Vicat’s plunger as shown in Fig. 1. Lower the plunger gently so as to touch the surface of the test

block and quickly release the plunger allowing it to sink into the paste. Measure the depth of

penetration and record it. Prepare trial pastes with varying percentages of water content and

follow the above steps until the depth of penetration becomes 33 to 35 mm.

B. Setting time of cement

Initial setting time is required to delay the process of hydration or hardening. It is the time period

between the time water is added to cement and time at which needle having 1 mm2 cross – sectional area fails to penetrate the cement paste, placed in the Vicat’s mould, 5 mm to 7 mm

from the bottom of the mould. Final setting time is the time when the cement paste completely



loses its plasticity. It is the time taken for the cement paste or cement concrete to harden

sufficiently and attain the shape of mould in which it is casted. It is the time period between the

time water is added to cement and the time at which needle having 1 mm2 cross-sectional area makes an impression on the paste in the mould but attachment having 5 mm diameter does not

make any impression.

This test is performed as per IS 4031(part 5):1988. According to IS 8112:2013, initial setting

time should not be less than 30 minutes and final setting time should not be more than 600

minutes for OPC 43 cement.

Fig. 1: Vicat’s apparatus for Normal Consistency.

Fig. 2: Vicat’s apparatus for Setting Time.

A neat cement paste with 0.85 P of water by weight of cement is prepared. P is normal

consistency of cement and weight of cement is 400 g. This cement paste is filled in Vicat’s

mould as shown in Fig. 2, resting on a non-porous base plate. This mould is placed under the rod

bearing the needle having cross sectional area of 1 mm2. The needle is gently lowered so that it

completely penetrates the test block. Time is recorded when this needle fails to penetrate the

block for about 5 mm measured from the bottom of the mould. Now needle is replaced with

annular attachment and time is recorded when needle within attachment leaves an impression

while the annular attachment fails to do so.

C. Fineness of cement

It is measured by sieving cement on standard sieve. The proportion of cement of which the grain

sizes are larger than the specified mesh size is thus determined. Fineness of cement has great

effect on the rate of hydration. Finer cement particles offers great heat of hydration and hence

faster development of strength.

This test is performed in accordance with IS 4031(part 1):1996. 100 g of cement sample is

sieved manually on 90 microns sieve as shown in Fig. 3 for 10 to 15 minutes. Weight of cement

retained on 90 micron sieve is recorded and fineness modulus of cement is determined.

D. Specific Gravity of cement

It is generally a ratio of density of cement to that of any known material. Generally

water is used as reference material but in this research, Kerosene oil is used because it does



not react with cement whereas water reacts with cement as soon as it came in contact .

Specific gravity of Kerosene oil is 0.79.

This test is performed in accordance with IS 4031(part 11):1988. Le-Chatelier flask as shown

in Fig. 4 of 250 ml capacity is used. 64 g of cement is used. Flask is filled with kerosene oil up to

upper mark (i.e. 1 ml) of graduations below the central bulb. After this 64 g of cement is poured

gently into the flask which results in increased level of Kerosene oil in the flask. The ratio of

weight of cement to displaced volume of kerosene gives the specific gravity of cement.

Fig. 3: 90 microns sieve Fig. 4: Le Chatelier flask

[2] Design Mix

It is the process of selecting suitable ingredients of concrete and determines the relative

proportions with the object of certain minimum strength as economically as possible. The

objective of concrete mix design is to achieve the stipulated minimum strength and to make the

concrete in the most economical manner. Cost wise all concretes depends primarily on two

factors, namely cost of material and cost of labor. Labor cost, by way of formwork, batching,

mixing, transporting and curing is normally same for good concrete. In this research design mix

is carried out for making M20 grade concrete. The process of making M20 concrete follows

the guidelines given in IS 10262:2009. Stipulations for proportioning are minimum water content

equal to 320 Kg/m, maximum water- cement ratio equals to 0.5 and maximum cement content

equals to 450 Kg/m3.

The replacement of fly ash has done with 0%, 5%, 10% and 15% by weight of cement.

The addition of waste plastic fibers by weight of concrete has been done with 0%, 0.5%, 1%,

1.5%.

48 cubes and 48 cylinders were casted and tested after 7 and 28 days for compressive strength and

split tensile strength.

MIX CALCULATIONS

For cubes



Volume of cube = 150*150*150 = 0.003375m^3

1. Amount of cement= (1*1.57*1440*0.003375)/5.5 = 1.39 kg

2. Amount of sand= (1.5*1.57*1600*0.003375)/5.5 = 2.31 kg

3. Amount of coarse aggregates= (3*1.57*1700*0.003375)/5.5 = 4.91 kg

4. W/C ratio= 0.5

5. Water required = 0.5*1.39 = 0.695 kg

Table 1. Quantities of ingredients in concrete for cubes

FA+WPF CEMENT SAND C.A WATER FA WPF

+0 1.39 2.31 4.91 0.695 0 0

5+0 1.320 2.31 4.91 0.695 0.070 0

10+0 1.251 2.31 4.91 0.695 0.139 0

15+0 1.182 2.31 4.91 0.695 0.208 0

0+0.5 1.39 2.31 4.91 0.695 0 0.047

5+0.5 1.320 2.31 4.91 0.695 0.070 0.047

10+0.5 1.251 2.31 4.91 0.695 0.139 0.047

15+0.5 1.182 2.31 4.91 0.695 0.208 0.047

0+1.0 1.39 2.31 4.91 0.695 0 0.009

5+1.0 1.320 2.31 4.91 0.695 0.070 0.009

10+1.0 1.251 2.31 4.91 0.695 0.139 0.009

15+1.0 1.182 2.31 4.91 0.695 0.208 0.009

0+1.5 1.39 2.31 4.91 0.695 0 0.139

5+1.5 1.320 2.31 4.91 0.695 0.070 0.139

10+1.5 1.251 2.31 4.91 0.695 0.139 0.139

15+1.5 1.182 2.31 4.91 0.695 0.208 0.139

For Cylinders

Volume of cylinder 0f size 150*300 = πr^2h = 3.14*0.075^2*0.3 = 0.0053m^3

1. Amount of cement = (1*1.57*1440*0.0053)/5.5 = 2.179 kg

2. Amount of sand = (1.5*1.57*1600*0.0053)/5.5 = 3.631 kg

3. Amount of coarse aggregates = (3*1.57*1700*0.0053)/5.5 = 7.716 kg

4. W/C ratio = 0.5

5. Amount of water required = = 0.5*2.179 = 1.089 kg

Table 2. Quantities of ingredients in concrete for cylinders

FA+WPF

(kg)

CEMEN

T (kg)

SAND

(kg) C.A (kg)

WATER

(kg) FA (kg)

WPF

(kg)

0+0 2.179 3.631 7.716 1.089 0 0

5+0 2.070 3.631 7.716 1.089 0.109 0

10+0 1.961 3.631 7.716 1.089 0.218 0

15+0 1.852 3.631 7.716 1.089 0.327 0

0+0.5 2.179 3.631 7.716 1.089 0 0.073

5+0.5 2.070 3.631 7.716 1.089 0.109 0.073

10+0.5 1.961 3.631 7.716 1.089 0.218 0.073

15+0.5 1.852 3.631 7.716 1.089 0.327 0.073

0+1.0 2.179 3.631 7.716 1.089 0 0.015

5+1.0 2.070 3.631 7.716 1.089 0.109 0.015



[3] Testing on fresh and hardened concrete

1. Slump Test

Slump is a measure indicating the consistency or workability of cement concrete. The vertical

subsidence of unsupported fresh concrete, flowing to the sides is known as slump. It gives an idea

of water content needed for concrete to be used for different works. A concrete is said to be

workable if it can be easily mixed, placed, compacted and finished. A workable concrete should

not show any segregation or bleeding. Slump flow test was performed as envisaged by BIS: 1199-

1959.

2. Compressive Strength of concrete

Cube specimens of size 150 mm were cast for compressive strength as per Indian standard

specifications BIS: 516-1959. After casting, all tests specimens were finished with steel trowel.

Immediately after finishing, the specimens were covered with sheets to minimize the

moisture loss from them. Specimens were demoulded after 24-hours and then cured in water at

approximately room temperature till testing. Compressive strength tests for cubes were carried

out at 7 and 28 days. All the specimens were tested in a Compression Testing Machine (CTM)

shown in Fig 6. The compressive strength was then calculated according to the formula

σ = P / A

Where, σ = Compressive Strength (N/mm2 );

P = Maximum load (N);

A = Cross section area of cube (mm2 )

Fig. 5: Slump Test

Fig. 6: Compression Testing Machine

3. Split Tensile Strength Test

10+1.0 1.961 3.631 7.716 1.089 0.218 0.015

15+1.0 1.852 3.631 7.716 1.089 0.327 0.015

0+1.5 2.179 3.631 7.716 1.089 0 0.219

5+1.5 2.070 3.631 7.716 1.089 0.109 0.219

10+1.5 1.961 3.631 7.716 1.089 0.218 0.219

15+1.5 1.852 3.631 7.716 1.089 0.327 0.219



Split tensile strength test is an indirect method of measuring tensile strength of concrete. It applies

a diametric, compressive force along the length of the cylindrical specimen. Concrete cylinder is

loaded in compression on its side along a diameter plane In CTM as shown in the Fig. 7.

Generally, failure occurs by the splitting of the cylinder along the loading plane.

From theory of induced tensile stress concepts, the following formula is obtained and recommended for the evaluation of the splitting tensile strength, is given by

Ft = 2P/piDL

Where,

Ft = Split tensile strength (MPa) at which the cylinder is split into two or more pieces

P = Ultimate load (N) at which the splitting of cylinder takes place

D= diameter of the cylinder (mm)

L= Length of the cylinder (mm)

This property is useful in estimating the concrete load-carrying capacity in tension, mainly due to

direct compressive forces on it.

Fig. 7: Split Tensile Strength Test

IV. RESULTS AND DISCUSSIONS

A. Normal Consistency of cement

Table 3 and Fig. 8 shows the Normal Consistency values for OPC 43 grade cement and cement

modified with fly ash:

Table 3. Normal Consistency of OPC 43 modified with FA

FA Replacement Level (%) Normal Consistency (%)

0 32

5 31

10 29

15 28



Fig. 8: Normal Consistency of OPC 43 modified with FA

B. Setting time of cement

Table 4 and Fig. 9 shows the initial and final setting time of OPC 43 grade cement modified with

waste FA

TABLE 4. Setting times of OPC 43 modified with FA

FA Replacement Level

(%)

Initial Setting Time

(Minutes)

Final Setting Time

(Minutes)

0 102 294

5 114 302

10 119 300

15 130 320

Fig. 9: Setting times of OPC 43 modified with FA

26

27

28

29

30

31

32

33

0 5 10 15

Series2

0

50

100

150

200

250

300

350

0 5 10 15

Initial Setting Time (Minutes)

International Journal of Modern Trends in Engineering and Research (IJMTER) Volume 07, Issue 01, [January – 2020] ISSN (Online):2349–9745; ISSN (Print):2393-8161


E. Fineness Modulus of cement

When 100 g of cement was sieved manually using 90 microns sieve, 2.3g cement got retained on

sieve. This gives fineness modulus (FM) of cement as 2.3. Following formula is used to determine the

Fineness Module of cement.

Weight retained on 90 microns sieve = 2.3 gms Total weight = 100 gms

Fineness Modulus (F.M) = 2.3

F. Specific gravity of cement

Weight of cement, W = 64 g

Initial reading after kerosene oil is poured, V1 = 1 ml Final reading after 64 g cement is poured,

V2 = 21 ml

Increase in volume = V2 – V1

= 21 – 1

= 20 ml

Specific gravity of cement = W/ (V2 – V1)

= 64/ 20

= 3.2

Thus, specific gravity of cement is 3

G. Slump Test Results

Table 5. Slump Values

FA (%) WPF (%) SLUMP VALUE

0

0 20 0.5 21.3

1.0 21.8

1.5 22

5

0 20

0.5 21

1.0 23

1.5 24

10

0 24.7 0.5 25

1.0 26

1.5 27

15

0 27 0.5 28

1.0 29

1.5 30



Fig. 10: Slump Test Results

H. Compressive Strength of Concrete

Compressive strength is the most valuable property of concrete, although in many practical cases

others characteristics, such as durability, impermeability, may in fact be more important. However,

incorporation of FA as partial replacement of cement improves the compressive strength of concrete

for optimum replacement level. For the 4 combinations (0%, 5%, 10%, 15%) of partially replacement

of cement with fly ash and addition of 0.5%, 1%, 1.5% in grade M20 the concrete was casted

and tested for its properties such as Compressive strength and Split Tensile Strength.

Table 6. compressive strength of concrete modified with FA and WPF

0

5

10

15

20

25

30

35

0 5 10 15

WPF(%)

SLUMP VALUE

FA(%)

WPF(%)

COMPRESSIVE STRENGTH(N/mm2)

7 days 28 days

0

0 20 28

0.5 21.3 28.76

1.0 22 30.3

1.5 22.7 32.50

5

0 23 34

0.5 23.5 38.96

1.0 24 39.2

1.5 24.3 40.37

10

0 25 36.34

0.5 25.4 32.38



Fig. 11: Compressive Strength of concrete modified with FA and WPF

Table 6 shows that the strength of concrete improvement up to the 10 % replacement with fly ash

by cement. Compressive strength of the concrete (average of 3 cubes) is relatively higher for (FA

10% : Cement 90 %) compared with concrete having only OPC cement . The higher strength of

replacement could be attributed to the fact that with maximum density, the void content is least

resulting in higher strength. Moreover, with high density, the paste in excess will help in better

compatibility leading to higher strength.

It is well known that the calcium silicate hydrate(C-S-H) gel is the main source of strength of

cement. After addition of FA to the fresh cement, it chemically reacts to the CH to produce

additional C-S-H gel which contributes to improve microscopic property of cement. The production

of more C-S-H gel in concrete with fly ash may improve the concrete properties due to the reaction

among FA and calcium hydroxide in hydrating cement.

1.0 26.2 35.93

1.5 27 43.24

15

0 27.4 40.23

0.5 28 32.66

1.0 28.31 35.70

1.5 29 18.13

0

5

10

15

20

25

30

35

40

45

0 5 10 15

WPF(%)

COMPRESSIVE STRENGTH(N/mm2) 7 days

COMPRESSIVE STRENGTH(N/mm2) 28 days



I. Split Tensile Strength of Concrete

Split tensile strength increased with increase in fly ash and addition of waste plastic fibers content

to a certain limit and then decreased with further increase in fly ash content and waste plastic fibers.

At all replacement levels considered in this study, split tensile strength FA and addition of WPF

concrete was more than the respective control mix tensile strength. These results agreed well with the

earlier researches. The increase in strength may be attributed to the pozzolanic reaction and improved

pore structure of concrete. This shows that replacement with fly ash and addition of WPF in concrete

significantly increases split tensile strength in concrete. Small reduction in the split tensile strength

was observed at 15% replacement level as compared to other replacement levels.

Split tensile strength results at 7 days and 28 days are shown in Fig. 12 and Table 7.

Table 7: Split Tensile Strength of concrete modified with FA and WPF

FA

(%)

WPF

(%)

TENSILE

STRENGTH(N/mm2)

7 days 28 days

0

0 1.54 1.90

0.5 1.90 2.00

1.0 2.20 2.90

1.5 2.90 3.20

5

0 2.20 3.00

0.5 2.48 2.90

1.0 2.97 2.83

1.5 2.04 2.83

10

0 1.30 2.20

0.5 1.64 2.97

1.0 2.00 2.90

1.5 2.16 2.83

15

0 1.50 2.50

0.5 1.71 2.35

1.0 2.02 3.85

1.5 2.85 4.90



Fig. 12: Split Tensile Strength of concrete modified with FA and WPF

V. CONCLUSION

In this work, need and importance of fly ash as cement replacing materials and addition of waste

plastic fibers has been discussed. Based on the literature review, characterization of fly ash was

carried out to find the suitability of fly ash as a pozzolanic material with addition of waste plastic

fibers in M20 mix of concrete. This research work recorded experimental results of test specimens

prepared by using cement partially replaced with FA with alternate percentages of WPF. The

following major conclusions can be drawn from this study:

1. The use of FA as partial replacement of cement and addition of WPF by volume of concrete decreases the normal consistency of cement.

2. The use of FA and WPF has insignificant effects setting times of cement.

3. The use of FA increases the workability of concrete.

4. The use of FA as partial replacement up to 10% increases the compressive strength of concrete.

5. The use of FA as partial replacement up to 10% and addition of 1% of WPF increases the tensile

strength of concrete

Future Scope

1. The strength of concrete replacing fly ash and adding waste plastic fibers can be carried out for

different concrete grades and different water cement ratios. 2. The replacement of fly ash can be increased upto 50% and optimum value can be calculated

which can fulfill every required properties of and hardened concrete.

3. The addition of waste plastic fibers can also be increased and strength properties can be increased

without reducing other required properties of concrete.

4. The temperature effect should also be checked in future study while increasing the percentage of

waste plastic fibers because of catching instant fire property during fire.

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

0 5 10 15

WPF(%)

TENSILE STRENGTH(N/mm2) 7 days



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Documents

PARTIAL REPLACEMENT OF CEMENT BY FLY ASH …...This test is performed in accordance with IS 4031(part 1):1996. 100 g of cement sample is sieved manually on 90 microns sieve as shown